Carpet weaving with improved coverage



Dec. 16, 1958 F. w. E. HOESELBARTH 2,364,408

4 CARPET WEAVING WITH IMPROVED COVERAGE Filed Aug. 13, 1956 2 Sheets-Sheet 1 7 35 56 3377 56 3 57 g l 32 a l I 55$ 5' I w {0 5 i 5 f Li I; "'3 i E 802 It, 1 4 1L 5 g 22 L0 MZ5384O638028 a sa 40 58 38 as iy Pram Ari INVENTOR.

1? j .feAkv/r w, E. #05551 BAP! Mag 56 56 ATTORNEYS.

Dec. 16, 1958 F. w. E. HOESELBARTH 2,864,403

CARPET WEAVING WITH IMPROVED COVERAGE Filed Aug. 13, 1956 2 Sheets-Sheet 2 7' JNVENTOR.

F/PA/YK M 6 19055515497 2,864,408 CARPET WEAVI NG WITH IMPROVED CUVEBAGE Frank W. E. 'Hoeselbarth, Carlisle, Pa., assignor to C. H.

Masland & Sons,Carlisle, Pa., a corporation of llennsylvania Application August 13, 1956, Serial No. 603,761 3'Clainis (Cl. 139-39) The present invention relates to Weaving pile carpets.

This application has been divided and the subject matter relating to the fabric is being embodied in a divisional application for Carpet With Improved Coverage, Serial No. 680,518, filedAugust 27, 1957. p

A purpose of the invention is to obtain improved coverage in pile carpets having a plurality of warps raised in the pile in staggered relation.

A further purpose is to weave a pile carpet having stutter warp ends in each dent, one-or preferably two opposite binder warp ends in each dent, and selectively one or more pile warp ends in each dent, the pile warp ends being raised alternately in the pile, to thread-in a pile warp end of only one set in some of the dents, to thread in a pile warp end of the other set in some of the dents, to thread in a pile warp end of both sets in some of the dents and to reverse the lateral relationship between the stuflfer warp ends and the pile warp ends in the dents having only one pile warp end as compared with those having pile warp ends of both sets.

A further purpose is to weave a pile carpet, using two sets of pile warp ends, binder warp ends, stufl er Warp ends and wefts, by threading in at least one stutter warp end in each dent, threading in at least one binder warp end in each dent, threading in in the first, fourth, seventh,

etc. dents and'end of the first pile warp set on one side of thestulfer warp end and leaving an end out of the second pile warp set, threading in in the second, fifth,

eighth, etc. dents an end of the second pile warp set on theother side of the stutter warp end and leaving an end out of the first pilewarp 'set, threading in in the third, sixth, ninth, etc. dents an end of the first pile warp set on the other side of the stuffer warp end and an end of the second pile warp set on the one side of the'stulter warp end, interweaving the pile warp ends of both sets, the staffer warp ends, the binder warp ends and wefts, while-raising the pile warp ends of the two sets in the pile preferably over wires alternately in pile projections at different weft positions.

A further purpose is to produce a pile carpet having courses defined by recurring binder warp ends woven in the same direction, comprising two sets of pile warp ends alternately raised in the pile, at least one stutter warp end in each course, top and bottom wefts above and below the Stufier Warp ends and certain of the wefts tying in the pile warp ends, and at least one binder warp end woven in the same direction in each course and tying together the top and bottom wefts, the first, fourth, seventh, etc. courses having an end of the first pile war set on one sideof the stuffer warp end and having an end out of the second pile warp set, the second, fifth, eighth, etc. courses'having an end of the second pile warp set on the other side-of the stutter warp end and having an end out-of the first pile warp set, and the third, sixth, ninth, etc. courses having an end-of the first pile warp set on the other side' of the stutter warp end and having; an end of the second pilewa'rp set on the one side of the stuffer Warp end,

2,864,408 Patented Dec. 16, 1958 Further purposes appear invthe specification and in the claims.

1n the drawings I have chosen to illustrate one only of the numerous embodiments'in which my invention may appear, selecting the form shown from the-standpoints of convenience'in illustration, satisfactoryoperation and cleardemonstration of the principles involved.

Figure I is a diagrammatic plan view showing a threadin diagram for weaving according to the invention.

Figure 2 is a conventional warpwise weave diagram showing the stutter warp ends, binder warp ends, pile warp ends and wefts of a dent havingtwo pile warp ends, and also showing the stuffer'warp ends, binder warp ends, pile warp ends and-wefts of-a dent having .one pile-warp end, with the pile warpend in the next dent having only one pile warp end.

Figure 3 .is a photograph of'the face of a 'pile carpet woven in accordance with the invention. I

Figure 4 is a diagram of the tops of adjoining loops of pile warp ends in the face of a carpet formed without using the principles of the invention,

Figure 5 is a view similar to Figure 4 showing the use of the principles of the present invention.

Describing in illustration but not in limitation and referring to the drawings:

in the prior art, in accordance with my previous patents selective thread-ins have been used, employing different lateral densities of pile warp ends in different dents or courses. 7 I v v I have endeavored to utilizethis principle to produce novel effects in pile carpets, especially in the velvet or tapestry weave, utilizing an end in of pile warp A in one dent, an end-in of pile warp B in the next dent, and an end in-of pile warp A and an end in of pile War-p B in the next dent. Unless very high pile or very full pile yarns are used, difliculty has been encountered in obtaining adequate coverage. --A crowding eflect-occurs, and grinning through the face of the fabric .to expose the back is likely to be exhibited. This constitutes a limitation on the otherwise desirable staggered weaving'according to a thread-in as above described.

I have discovered that this difficulty can be overcome, and greatly improved coverage can be obtained with elimination of the crowding elfect, even in relatively low pile carpets and in carpets using relatively compact pile yarns, if the lateral relation of the pile ends to the stutter warp ends in the dents or courses is reversed in the dents having only one pile warp end as compared to the dents having 'pile warp ends of both sets. Since the pile warp ends of the diflferent sets are raised in'the pile over wires or as terry loops or otherwise alternately, the loops or pile projections tend to laterally enga-ge and displace one another above the back at crossing points, and unless the reversal takes place as above-described very poor coverage is obtained, but with the reversal the coverage is excellent.

Considering the weave illustrated'in Figure l, I'show a reed 20 having splits 21 which divide the draw up into dents 22, 23, 24, 25, 26, -27, 28 and 30, which are simply intended to be representative dents in the fabric starting at any desired point. There also is a pile warp heddle 31 having eyes'32 through which are threaded pile'wa-rp ends 33, and-a pile warp heddle 34 having eyes 35 through which are threaded pile warp ends 36. (See also Figure 2.)

Each one of the dents as shown has a stutter, warp end 37 manipulated by a separate heddle, or if preferred manipulated 'by long slots on the heddles "3-1 and 34 :in accordance with the pr-inciples of :my U.- -'S. vPatents 2,709,458 and 2,709,460, both granted May 31, 1955; and 2,713,355 and 2,713,356 both granted July 19, 1955.

Each of the dents also has a binder warp end 38 manipulatedby a binder warp heddle (not shown) and a binder warp end 40 manipulated by another binder warp heddle (not shown). While the particular weave here illustrated utilizes two binder warp ends woven in opposition, it will be understood that it is immaterial, from the standpoint of the present invention, whether two binder warp sets are used or a single binder warp set is woven in opposition to the stutfer warp, as well known.

Unlike the usual type of thread-in which is the same in each dent or course, in the fabric of the present invention the thread-in varies sequentially. Thus in some dents, in this case dents 22, and 28, etc., the pile warp ends 36 threaded through the eyes of pile warp heddle 34 lie on the right of the stutter warp 'end, or the side toward the binder warp ends 38 and 40.

In some other dents, in this case dents 23, 26 and 30, etc., the pile warp ends 33 of the other set are threaded through eyes 32 of the pile warp heddle 31. In both of the sets of dents above referred to, where there are ends 36 of one pile warp set there are no ends of the other pile warp set, and where there are ends 33 of the other pile warp set there are no ends of the one pile warp set.

On the other hand, in other dents or courses, ends of both pile warp sets are present. Thus in dents 24, 27, etc., there are ends 36 of one pile warp set and ends 33 of the other pile warp set. Here, however, an important departure has been made. Whereas in the dents having only ends 36 of one pile warp set, the pile warp ends lie to the right of the stutter warp end or adjoining the binder warp ends, and in the dents having only ends 33 of the other pile warp set the pile warp ends lie to the left of the stuffer warp end or remote from the binder warp ends, the relationship of the oppositely woven pile warp ends in the dents having ends of both pile warps is reversed. Thus in dents 24 and 27 pile warp end 36 is on the left of the stuffer warp end or remote from the binder warp ends and carried through a different eye of pile warp heddle 34. Likewise pile warp end 33 is reversed and now lies on the right of the stuifer warp end or on the side adjoining the binder warp ends and is threaded through a different eye of the pile warp heddle 31. This is suggested by the dot-and-dash eyes and arrows in Figure l. 7

While of course this principle of combining dents having only an end of pile warp A placed, say, on the right of the stuffer warp end, and dents having only an end of pile warp B placed, say, on the left of the stuifer warp end, with dents having an end of pile warp A placed, say, on the left of the stuffer warp end and an end of pile warp B placed, say, on the right of the stuffer warp end may be varied to produce different sequences or locations to suit the requirements of the designer, it will be evident that best results will be obtained by having periodic lateral repeats which may consist of the following:

(1) A dent or course having only an end of pile warp A to the right of the stutter warp end;

(2) A dent or course having only an end of pile warp B to the left of the stutfer warp end;

(3) A dent or course having an end of pile warp A to the left of the stutter warp end and an end of pile warp B to the right of the stuifer warp end.

If these are repeated laterally, the dents mentioned in paragraph (1) will be the first, fourth, seventh, etc. dents, repeating this series across the fabric; the dents mentioned in paragraph (2) will be the second, fifth and eighth, etc. dents, repeating this series across the fabric, and the dents mentioned in paragraph (3) above will be the third, sixth, ninth, etc. dents, repeating this series across the fabric.

In weaving the carpet as shown in Figure 2, the principles of weaving with staggered pile warp sets will be followed. Thus at the position of insertion of upper weft 41 a double shed is formed. Pile warp ends 33 are raised to the upper position, and binder warp ends 40 are raised to the mid-position, forming an upper shed, and all other ends are lowered, forming a lower shed. Wire 42 which may be of any suitable character, cutting, non-cutting, high, low, wavy, straight, flag or otherwise, is inserted in the upper shed, and a shot of upper weft 41 is inserted in the lower shed.

In the next step corresponding to the position of lower weft 43, binder warp ends 38 are lowered and all other ends are raised half way, forming a lower shed, and a shot of lower weft 43 is inserted in the lower shed.

At the next position corresponding to the position of upper weft 41', a double shed is formed. Pile warp ends 36 are fully raised and binder warp ends 38 are raised half way, forming an upper shed, and all other ends are lowered, forming a lower shed. The wire 42 is inserted in the upper shed and a shot of weft 41' is inserted in the lower shed. This wire may be of any suitable character, as in the case of wire 42.

In the next step corresponding to the position of lower weft 43, binder warp ends 40 are lowered and all other ends are raised half way, forming a lower shed, and a shot of weft 43 is inserted in the lower shed.

The further weaving is a repetition of that just described.

While I have illustrated raising of the staggered pile warp sets over wires to form pile projections 44, it will be evident that it is immaterial from the standpoint of the present invention whether such pile projections are formed by raising over wires or by terry weaving or otherwise.

Figure 3 illustrates the face of a pile carpet corresponding to Figures 1 and 2 which has been woven embodying the principles of the invention.

It will be evident that though the pile is a low pile, very good coverage is obtained due to the reversal eifect in the lateral thread-in and any tendency to crowding effect by the nonuniform density distribution of pile warp ends is largely overcome.

It will be evident that if the reversal of the position of ends 36 and 33 were not accomplished in dents 24, 27 etc., you would have pile warp ends 36 and 33 in adjoining relationship, tending to produce concentrated and poorly distributed pile. On the other hand, as shown in Figure 5, with the reversal of draw-up, in dents 24, 27 etc., there is an alternate distribution or a staggered distribution of pile projections spread out over the face of the fabric, so that the order of appearance is pile warp end 33, pile warp end 36, pile warp end 33 and pile warp end 36.

Accordingly a very unusual uniformity of distribution is obtained notwithstanding the nonuniformity of the thread-in.

In view of my invention and disclosure, variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art to obtain all or part of the benefits of my inven' tion without copying the method shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. The method of weaving a pile carpet, using two sets of pile warp ends, binder warp ends, staffer warp ends and wefts, which comprises threading in at least one stuffer warp end in each dent, threading in at least one binder warp end in each dent, threading in in the first, fourth, seventh, etc., dents an end of the first pile warp set on one side of the stuffer warp end and leaving an end out of the second pile warp set, threading in in the second, fifth, eighth, etc., dents an end of the second pile warp set on the other side of the stuffer warp end and leaving an end but of the first pile warp set, threading in in the third,

sixth, ninth, etc., dents an end of the first pile warp set on said other side of the stutter warp end and an end of the second pile warp set on said one side of the stutter 5 warp end, interweaving the pile warp ends of both sets, the stutter warp ends, the binder warp ends and wefts while raising the pile warp ends of the two sets alternately in pile projections at different weft positions.

2. The method of claim 1, in which the pile warp ends are raised alternately and wires are inserted thereunder to form the pile.

3. The method of weaving a pile carpet using two sets of pile warp ends, binder warp ends, stulfer warp ends and wefts, which comprises threading in at least one binder warp end in each dent, in some of the dents threading in an end of the first pile warp set and leaving an end out of the second pile warp set, in others of the dents threading in an end of the second pile warp set and leaving an end out of the first pile warp set, in others of the dents threading in both an end of the first pile warp set and an end of the second pile warp set, the ends of the first and second pile warp sets in the dents having only one pile warp end being on opposite sides of the stuffer warp end from the corresponding ends of the pile warp sets in the dents having ends of both pile warp sets, and interweaving the pile warp ends of both sets, the stutter warp ends, the binder warp ends and wefts while raising the pile warp ends of the two sets alternately in pile projections at difierent weft positions.

References Cited in the file of this patent UNITED STATES PATENTS 2,714,902 Hoeselbarth Aug. 9, 1955 2,754,856 Hoeselbarth July 17, 1956 2,765,001 Hoeselbarth Oct. 2, 1956 2,777,468 Jackson Jan. 15, 1957 

